dana 18 problems

i just got my dana 18 guts put into a dana 20 case because i broke the case on the d18 but the case has the twin stick set up and its hard to shift from 2wd and 4wd some time does the case need to be put into neturel to shift first or is there any adjustment????????????????

 

You should look up the repro shift decals on herm's site or maybe Morris 4x4. Much easier than trying to explain it in txt.
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wats herms site

 

Hermtheoverdriveguy.com
And you'll find that the 2wd to 4wd locks into 4wd when the hi, N, low lever is in low. I'm not sure the decals illustrate this feature.
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i know the shifter pattern but the levers are hard to shift sometimes . think its because it new or just rebuilt ?

 

Sounds pretty normal, try shifting into reverse and letting the clutch out and then try shifting the transfer case. Sometimes when the hubs are locked the transfer case tends to bind up also

 

I've found that I can shift into 4WD at just about any speed if I first load the drive line by, while rolling in gear, giving it a little gas to shift the weight back then push in the clutch and it shifts right in.
To shift out, again while rolling in gear, I'll give it a little gas then let off the gas and allow the weight to shift forward then push the clutch in and it shifts right back out.
Give it a shot, it works on just about every gear driven transfer case I've tried. Even worked on the chain driven case in my dads old Bronco II.